Modular Electrical Plug Connector Assembly for Motor Vehicle Control Units
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Solution Overview
Problem
The increasing complexity of motor vehicle control units with a large number of electrical contacts and sensors leads to unforeseeable distortions in connector arrangements, requiring extensive rework and increasing manufacturing costs, while existing solutions do not offer a cost-effective or flexible way to produce and modify plug-in connector arrangements.
Innovation Solution
A modular electrical connector assembly using a module carrier and plug-in modules with individually designed and positioned contact elements, allowing for precise connection and assembly through welding or gluing, which reduces distortion issues and simplifies the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If control units are equipped with a large number of electrical contacts (approx. 300 contacts), then the functionality and control capability are improved, but the manufacturing complexity and distortion of connector arrangements increase
Solution Approach 1:
The connector arrangement is divided into multiple individual connector components, each with a limited number of contacts. These segmented connectors are arranged in a structured layout with standardized spacing, allowing the system to achieve high contact count (300 contacts) without the manufacturing complexities of a single large connector. The segmentation enables independent manufacturing and assembly of each connector component.
2Manufacturing precision
If extensive rework is performed on injection molding tools to comply with position tolerances, then manufacturing precision is improved, but production time and costs increase
Solution Approach 1:
Positioning elements and locating features are pre-integrated into the connector components and housing structures during the initial molding process. The connector components include built-in positioning features that ensure correct alignment when assembled, eliminating the need for subsequent rework or adjustment of injection molding tools. This preliminary incorporation of positioning functionality maintains manufacturing precision without sacrificing productivity.
3Reliability
If pin contacts protrude 8 mm from the plastic housing, then connection reliability is improved, but the risk of damage and manufacturing complexity increase
Solution Approach 1:
Instead of having pin contacts protrude significantly in one dimension (8 mm from housing), the connector design utilizes a multi-dimensional approach with contacts arranged in multiple rows and columns across the connector face. The positioning elements and locating features distribute the connection function across multiple dimensions, reducing the protrusion distance requirement while maintaining connection reliability through improved geometric distribution and structural support.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The modular design enables cost-effective and precise integration of plug-in modules, reducing tool correction costs and allowing for greater design flexibility, while ensuring reliable and durable electrical connections.
Implementation Method 1
the pin contacts are placed in the injection mold and encased in plastic during the injection molding process
Implementation Method 2
The plug-in modules are positioned in relation to one another in the module carrier. Furthermore, the first and second plug-in modules are each permanently connected to the module carrier by a joining process
Implementation Method 3
The plug-in modules are positioned in relation to one another in the module carrier. Furthermore, the first and second plug-in modules are each permanently connected to the module carrier by a joining process
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The invention relates to a modular electrical plug connector assembly for control units in a motor vehicle, comprising a module mounting (4) and at least one first (6) and one second plug-in module (8), wherein the first (6) and the second plug-in module (8) are arranged side-by-side and/or consecutively in the module mounting (4). The first plug-in module (6) is provided with a first plug housing (12), wherein the first plug housing (12) is configured to accommodate a first electrical plug connector. The second plug-in module (8) is provided with a second plug housing (14), wherein the second plug housing (14) is configured to accommodate a second electrical plug connector. The first plug housing (12) is provided with an electrically conductive first contact element (18), and the second plug housing (14) is provided with an electrically conductive second contact element (20). According to the invention, the first plug-in module (6) and the second plug-in module (8) are positioned relative to one another in the module substrate, and the first (6) and the second plug-in module (8) are each permanently attached to the module mounting (4) by means of a fusion process.